Printed by Kawasaki under document number 93209-00240, this 264-page shop manual is the factory book for the 80ZV wheel loader, now supplied as a Kawasaki 80ZV shop manual PDF. The torque converter and transmission group takes up a large share of the pages and takes both assemblies through complete teardown and reassembly. The hydraulic group covers pump removal and the boom, bucket and steering cylinders. Chassis, power, brake and operator station groups follow the same pattern: removal and reinstallation, disassembly, then a service standard listing the limits you measure against. Set the parking brake actuator clearance at 1 mm (0.04 in.), and expect the hydraulic pump to deliver 64.5 cm3/rev at up to 2,400 rpm when you check its output. A parked loader burns hours you never get back. Your copy is bookmarked by group and text-searchable, downloads straight away and helps put the 80ZV back on the pile.
What's Inside This Kawasaki 80ZV Manual
| System | Pages | Key Topics |
|---|---|---|
| Chassis Group | 17-44 | Removing and Reinstalling Deck, Removing and Reinstalling Fuel Tank, Removing and Reinstalling Hydraulic Tank, Removing and Reinstalling Engine Room, Removing and Reinstalling Cab |
| Power Group | 45-104 | Removing and Reinstalling Radiator, Removing and Reinstalling Engine, Removing and Reinstalling Propeller Shaft, Removing and Reinstalling Air Cleaner |
| Torque Converter & Transmission Group | 105-160 | Removing and Reinstalling Torque Converter and Transmission Assembly, Disassembling and Reassembling Torque Converter Assembly, Disassembling and Reassembling Transmission Assembly |
| Hydraulic Group | 161-220 | Removing and Reinstalling Hydraulic Pump Assembly, Removing and Reinstalling Boom Cylinder, Removing and Reinstalling Bucket Cylinder, Removing and Reinstalling Steering Cylinder |
| Brake Group | 221-252 | Removing and Reinstalling Unloader Valve, Removing and Reinstalling Valve Assembly, Removing and Reinstalling Accumulator, Removing and Reinstalling Brake Valve |
| Operator Station Group | 253-264 | Disassembly & Reassembly, Service Standard |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Retainer bolt (16) | 230 N-m (23.5 kgf-m) (170 lb-ft) | p. 19 |
| Hydraulic pump theoretical discharge | 64.5 cm3/rev (3.9 in3/rev) | p. 157 |
| Parking brake actuator clearance | 1mm (0.04in.) | p. 33 |
| Solenoid valve nut tightening torque | 10 N-m (1.0 kgf-m) (7 lb-ft) | p. 178 |
| Hydraulic pump maximum operation speed | 2,400 min-1 (rpm) | p. 157 |
| Bolt (bracket) | 73.5 N-m (7.5 kgf-m) (54 lb-ft) | p. 237 |
| Lock nut (stopper bolt) | 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) | p. 237 |
| Retainer bolts (park brake actuator) | 53 N-m (5.4 kgf-m) (39 lb-ft) | p. 239 |
| Head bolt of magnetic clutch | 18 N-m (1.8 kgf-m) | p. 260 |
| Air compressor (with magnetic clutch) T2 | 18 N-m (1.8 kgf-m) | p. 260 |
| Fuel Tank Capacity | 271 L | p. 19 |
| Transmission Oil Capacity | 35 L | p. 107 |
Kawasaki 80ZV Common Problems This Manual Covers
Kawasaki 80ZV service brake friction plates and steel plates worn, piston stroke out of range
Push the piston back and, with the wheel bearings adjusted correctly, check dimension A (piston end face to wheel hub end face) against 100.25 to 101.40 mm and piston stroke B against 1.15 to 3.40 mm on page 238. Then check each plate against page 250: steel plate 4.9 mm standard with a 4.4 mm wear limit, friction plate 7.4 mm standard with a 5.9 mm wear limit, brake disc 17.3 mm standard (brake applied) with a 15.1 mm wear limit. Replace any part worn to its limit.
Manual Section: Brake Group p. 238Parking brake shoe lining worn thin or brake drum deflection out of limit
Inspect the drum and shoes against the service standards on page 251: replace the lining when it wears to the 2.95 mm limit (6.15 mm standard), and replace the drum if deflection reaches 0.38 mm or more. For removal and reassembly follow page 244, torquing the propeller shaft bolts to 142 N-m (105 lb-ft) and the adjustment hole bolt (6) to 94 N-m (69 lb-ft).
Manual Section: Parking Brake Removal and Reinstallation p. 251Parking brake actuator linkage out of adjustment, linkage dimension A incorrect
With the parking brake off, measure linkage dimension A and adjust the link until it is 87 mm (3 27/64 in.), following page 240. The park brake actuator weighs 8 kg (18 lbs); when reinstalling it, torque the retainer bolts to 53 N-m (39 lb-ft) per page 239.
Manual Section: Brake Group p. 240Brake accumulator charging pressure low, air in brake circuit after accumulator or brake valve replacement
Stop the engine and depress the brake pedal until there is no brake pressure before you disconnect any accumulator or brake valve hoses. Check accumulator nitrogen charging pressure against 2.9 MPa at 20 °C (68 °F) on page 231, correcting for ambient temperature with the formula given there, and check for gas leaks. Completely bleed the brake line after reinstalling the accumulator or brake valve, and confirm the brakes respond before the machine goes back to work.
Manual Section: Accumulator Removal and Reinstallation p. 231Pilot valve coil magnet resistance out of spec or pilot valve solenoid loose in the hydraulic pilot circuit
Measure the resistance of each pilot valve coil magnet assembly with a multimeter: it should be 138 Ω at normal room temperature (20 °C) per page 188, lower in extreme cold and higher at operating temperature. Torque the pilot valve solenoid to 42 N-m (31 lb-ft) following page 185, and check the pilot valve adapter at 36 N-m (27 lb-ft) on page 183.
Manual Section: Hydraulic Group p. 188Transmission gear pump gear top and side clearance to housing worn beyond standard
Measure the transmission gear pump against page 157: top clearance between gear and housing 0.08 to 0.11 mm, side clearance 0.03 to 0.073 mm (measured with the gasket removed), backlash between gears 0.2 to 0.3 mm. Replace the pump if any value is out of standard. Theoretical discharge is 64.5 cm3/rev. Torque the pump fixing bolts to 59 N-m (43 lb-ft) on reassembly.
Manual Section: Torque Converter and Transmission Group p. 157Frequently Asked Questions
What are the torque specifications for the hexagon bolts used on the Kawasaki 80ZV?
The manual gives hexagon bolt tightening torque tables on pages 5 and 6. For example, a metric M8 coarse-pitch (1.25) bolt of strength 8.8 takes 26 N-m (2.7 kgf-m), while an M33 fine-pitch (2.0) bolt of strength 10.9 takes 3,040 N-m (310 kgf-m). p. 5
What is the procedure for bleeding air from the brake oil line?
Start and run the engine to build brake accumulator pressure, then shut it off. Connect a clear vinyl tube to the air bleeder nipple, loosen it slightly and press the brake pedal several times; when oil flows from the nipple, close it. After that, each time you press the pedal, open the nipple to discharge a little oil and close it immediately. Repeat until there is no air in the oil, and completely bleed each wheel. p. 61
What is the standard clearance for the boom cylinder pin on the Kawasaki 80ZV?
The standard clearance for the joint section between the boom and the boom cylinder is 0.101 to 0.217 mm (0.0039 to 0.0085 in.). If the clearance exceeds the tolerance of 1.0 mm (0.0393 in.), the part should be replaced. p. 39
How do I adjust the bucket positioner switch clearance on the Kawasaki 80ZV?
The standard clearance for the bucket positioner switch is 5 ± 2 mm (0.196 ± 0.078 in.). If the clearance is outside this range, it requires adjustment. p. 42
What is the tightening torque for the steering valve retainer bolt on the Kawasaki 80ZV?
The standard tightening torque for the steering valve retainer bolt is 49 N-m (5 kgf-m) (36 lb-ft). p. 218
How is this Kawasaki 80ZV Shop Manual delivered?
Straight to your device: 264 pages of searchable Shop Manual, downloadable the moment payment goes through.
Can I print specific sections of this Kawasaki 80ZV Shop Manual?
Yes. Print a single page or a chapter for your own shop use, on letter or A4.
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